Regulator for automotive generators



May 9, 1944. w, R 2,348,263

REGULATOR FOR AUTOMOTIVE GENERATORS Filed March 20, 1942 4 Sheets-Sheet 1 INVENTOR Hi5 ATTORNEYS?) y 1944- w. J. RADY REGULATOR FOR AUTOMOTIVE GENERATORS Filed March 20, 1942 4 Sheets-Sheet 2 Ufa Ma llNVENTOR M71115? .1 F545;/ BY A? ,M; 41.. "ms ATTORNEYS May 9, 1944. w, J RADY 2,348,263 7 REGULATOR FOR AUTOMOTIVE GENERATORS Filed March 20, 1942 4 Sheets-Sheet 5 INVENTOR MY/z'am .1 R503/ W M! M HlS- ATTORNEYEI I Patented May 9, 1944 REGULATOR FOR AUTOMOTIVE GENERATORS William J. Rady, Anderson, Ind., assignor to General Motors Corporation, Detroit, Mich a corporation of Delaware Application March 20, 1942, Serial No. 435,560

3 Claims.

This invention relates to apparatus for controlling the circuit between the storage battery and the generator and for regulating the generator. The circuit connections are controlled by the reverse current relay which closes when the generator voltage exceeds the battery voltage and disconnects the generator from the battery when the generator voltage falls below the battery voltage. The generator is regulated by a voltage regulator, or by a voltage regulator and a current regulator. The relay and the regulator or regulators are assembled together on a single mounting bracket.

One object of the present invention is to provide for the facile mounting of the regulator and relay units upon the mounting bracket and for connecting these units into the battery charging system. In order to accomplish this object I provide the relay and regulator units with plug terminals adapted to be received by sockets in the mounting base. These plug and socket connections are adequate for carrying all currents of the system with the exception of the battery charging current. The connections which are required to carry battery charging current are made by terminal screws. In the case of the voltage regulator all of the connections are made with plugs and sockets. In the case of the current regulator two of the connections are with plugs and sockets and two are made by threaded studs carried by the regulator and project in the apertured conductors carried by the mounting bracket. In the case of the relay its voltage connection with the mounting bracket is made by plug and socket and its battery and generator connections are made with the use of screws. In this way the regulating units and the relay unit may be readily detached from the bracket whenever replacements are required.

Further objects and advantages of the present invention will be apparent from the following description, reference'being had to the accompanying drawings wherein preferred embodiments of the present invention are clearly shown.

Fig. 1 is a wiring diagram of a battery charging system including an instrument assembly comprising a mounting base, a voltage regulator, a current regulator, and a reverse current relay;

Fig. 2 is a wiring diagram of a battery charging system including an instrument unit comprising a mounting base, a voltage regulator, and

.a reverse current relay;

Fig. 3.isa plan view of an instrument unit comcurrent regulator and a relay as shown diagrammatically in Fig. 1;

Fig. 4 is a side view thereof;

Fig. 5 is a bottom view thereof;

Fig. 6 is a sectional view on line 6-4; of Fig. 4;

Fig. 7 is a plan View of an instrument assembly comprising a mounting base, a voltage regulator and a relay, as shown diagrammatically in Fig. 2;

Fig. 8 is a side view thereof;

Fig. 9 is a bottom view thereof;

Fig. 10 is a sectional view taken on the line Ills-ll] of Fig. 8 and showing a reverse current relay;

Fig. 11 is a plan view of .the relay shown in Fig. 10;

Fig. 12 is a bottom View thereof;

Figs. 13 and 14, respectively, are simplified diagrams of the circuits shown in Figs. 1 and 2, re- ,spectively.

The voltage regulator will first be described with reference to Figs. 1 and 5. The base of the regulator, not shown, includes a sheet of hard insulating material through which three plug terminals 2|, 22 and 23 project and are spaced in .a manner as shown in Fig. 5. As shown diagrammatically in Fig. l, the regulator magnet .and contact assembly comprises an L-shaped magnetizable bracket 30 one leg of which supports a magnet core 33. The other leg is provided with ears 40 to which are attached leaf spring blades or leaves 42 and 43 carrying an armature M.

The blade '43 has its free end inclined upwardly away from the armature 44 and carries a contact 50 having a spherical face for engaging a face of a contact 5|. The contact 5| is resiliently supported, in any suitable manner, relative to the contact 50 so as to have a wiping action between them before they are separated and also after they are brought together. This wiping action assists in keeping the contact surfaces in good condition.

The winding of the voltage regulator comprises a generator voltage responsivecoil 34a and a field current carrying coil 34b, as shown at the left of Fig. 1. One end of coil 34a is connected to core 33, the other end with a wire 66 which is connected with the terminal 22. The coil 34b is connected by a wire '61 with a bracket, indicated byreference character 53, carrying the contact 5|. The other end of thecoil 34b is connected by a wire 66 with plug 2|. The frame 30 is connected by a lead 69 with plug 23. The regulator inits entirety is designated by numeral 10. In Fig. 1 the unit is represented by the parts included with the dotdash rectangle I0.

The current regulator designated in its entirety by numeral 80 is like the voltage regulator I in many respects. Where the parts of the current regulator are exactly like those of the voltage regulator similar reference numerals with the character a added have been used to designate the similar parts. The current regulator differs from the voltage regulator in that a core 331: is surrounded by one magnet coil 84 of relatively coarse wire having its ends connected respectively with threaded terminal studs 85 and 86. The regulator magnet and contact assembly com prises the L-shaped magnetizable bracket 30a one leg of which supports a magnet core 33a. The other leg is provided with ears 40a to which are attached leaf spring blades or leaves 42a and 43a carrying an armature 44a. Plug 83 is connected by a wire 83a with frame 30. Plug 8| is directly connected by wire 8Ia with bracket 53 which carries contact I.

The contacts of either regulator control the opening and closing of a short-circuit around a resistance unit in the field circuit of the generator to be controlled.

The regulator units I0 and 80 are adapted to be associated with reverse current relay 80 with reference to Fig. 1 and Fig. 6. The relay 90 comprises a metal base 9| located between an insulating plate 82 on the underside and an insulating plate 83 on the upper side. These plates together with the metal base 8| are secured together by rivets 94 and 95 which also serve to attach terminal plates 86 and 91 respectively. Against the insulating plate 93 is located a magnetizable frame I00 to which is secured an armature assembly spaced apart by a member I02 and secured together by a screw I0 I. A flexible metal hinge I03 is riveted to the plate member I02 and an L-shaped magnetizable armature I04 having a portion overlying a pole piece I05 of a core I06 which serves to attach the frame I00 to the assembly of plates 9|, 92 and 03. For this purpose the core I06 is provided with a portion of reduced diameter I01 extending through the plates 93 and 0| and merging with a portion of still further reduced diameter I08 extending through a washer I09. The portion I08 is circularly staked at IIO to confine the parts I00, 83, SI and 82 between the main portion of the core I06 and the washer I09. The lower portion III of core I06 provides a plug connection for the relay 90. Rivets II2 connect the armature I04 with the left end of a leaf spring II3 carrying a contact II4 for engaging a contact II5 carried by a bracket II6 connected by the rivet 94 with terminal plate 96. The core I06 is surrounded by a voltage coil II'I connected at II8 with core I06 which is connected with plug III. The other end of coil II! is grounded by connecting it with the plate 9I. The plate 82 is grounded by providing it with integral ears 9Ia adapted to be electrically connected with the mounting bracket I20. The downward movement of the armature I04 toward the pole I05 is resisted by leaf spring 104a. Attached at its left end to the armature I04 and bearing against its right end is a bendable sheet metal stock I04b supported by the magnet core I06. The core I06 is surrounded by a coil II9 having one end connected with the frame I00 and the other end 1 connected to a rivet 85 and therefore with termiadapted to be mounted together upon a mounting bracket I20 supporting socket members I2I, I22 and I23 respectively for receiving the plugs 2|, 22 and 23 of the voltage regulator 10. Plugs 2|, 22 and 23 extend through snugly fitting holes in insulating plate I24 secured against the under side of bracket I20. Sockets I2I and I22 are insulated from each other and from the bracket I20 and socket I23 is electrically connected with the bracket I20 by rivet I23d. Socket I2I is connected with socket I83 for receiving plug 83 of current regulator by a metal plate I25. Plate I25 is secured to the bracket I20 by rivets I26 and I21, but insulated therefrom. Socket I22 is connected by a strap I28 with socket 2H for receiving plug III of relay 80. Strap I28 is secured to mounting bracket I20 by rivet I29 and rivet I30 but is insulated from the bracket. Plug al of current regulator 80 is received by socket I8I electrically connected with terminal plate I3I secured to bracket I20 by rivets I32 but insulated therefrom. Resistance I33 controlled by the contacts of the current regulator 80 is connected between plate I25 and plate I3I. Resistance I34 controlled by the contacts of voltage regulator 10 is connected between the plate I3I and grounded by the mounting bracket I20. The threaded stud terminal 86 of regulator 80 passes through a hole in terminal plate I86 and receives a nut 86a for securing stud 86 to plate I86. Threaded stud of the regulator 80 passes through a hole in strip I85 and is secured thereto by a nut 85a. Strip I85 is connected by a screw 9111 with terminal plate 81 of relay 80, said plate being made accessible by providing the mounting bracket I20 with an aperture 81b. A screw 86a cooperates with a washer 86b and terminal plate 96 of relay to connect the plate 86 to a wire 860, Fig. 1, connected with a washer I86b to connect to the plate I86 with a wire I860 connected with one of the main terminals of generator G, the other main terminal being grounded. A screw I3Ia cooperates with a washer I3Ib to secure to the plate I3I with a wire I3Ic connected with the field winding F of generator G. The holes in the metal mounting bracket I20 are spaced according to the required spacing of plugs 2I, 22, 23, 6|, 83, III and the threaded studs 86 and 85 and provide clearance so that no electrical connection is made between the mounting bracket and any of these connectors. The holes in the insulating plate I20 are similarly spaced but these holes closely fit the plug or stud connectors and thus guide the connectors into their proper sockets or holes in conducting plates.

The voltage regulator 10 is mechanicallydisconnected from the mounting bracket and electrically disconnected from the sockets carried thereby by pulling the regulator away from the mounting bracket. There are no nuts to be loosened. The contact pressure between the sockets and the plugs of the voltage regulator is suillcient to carry the small amount of current required to be carried across these parts.

Before the current regulator 80 can be mechanically disconnected from the mounting bracket and electrically disconnected from the socket and conducting plates thereof, the nuts 85a and 86a must be removed from the studs 85 and 86.

Before the relay 80 can be mechanically disconnected from the mounting bracket and electrically disconnected from the single socket carried thereby the screw 81a must be removed.

From the foregoing it is apparent that the disconnection of the voltage regulator requires no nuts; and the removal of the relay requires only the removal of one screw. To replace the relay 90, however, it must be disconnected from the battery by unscrewing the nut 96a. It is, therefore, apparent that the removal of the instrument for a replacement thereof is greatly facilitated.

In an instrument assembly comprising a voltage regulator II! and a cut-out relay 90 and a mounting bracket 220, the arrangement of the sockets I2Ia, 122a and I.23c for receiving the plugs 2 I, 22 and 23 of the voltage regulator is the same as has been described. On referring to Fig. 9 it will be seen that socket I2Ia is electrically connected with terminal plate 22I, connected by screws 22Ia and wire 22 Ib with field F of generator G. The voltage regulator resistance I34a. is connected between plate HI and ground provided by bracket 220. Socket I230 is grounded by the attached rivet I23d. Socket I22a is connected by a strap 222 with the socket 2| Ia which receives plug II I of the relay 90. The terminal plate 91 of the relay 90 extends outwardly in Fig. 9 which is to receive screw 910 by which a wire 91b is used to connect a terminal of generator G. In the combination shown in Fig. 2 the voltage regulator and the relay 90 can be removed from the mounting bracket 220 without first removing any screws or nuts. However, the relay can not be disconnected from the leads to the generator and battery without first loosening the screws 96a and 91a.

From the foregoing it will be seen that when the instrument assembly is connected between the battery B and the generator G the electrical circuits and connections for a voltage regulator and a reverse-current relay is best shown in the simplified diagram Fig. 13. The diagram shows the voltage regulator II! having a first terminal 2| connected with the generator field F, a second terminal 22 connected with the generator-line and a third terminal 23 connected with ground. The magnet coil 34a of the voltage regulator is connected between the second terminal 22 and the third terminal 23. A pair of regulating contacts and 50 controlled by the magnet coil 34b are connected between the first terminal 2| and the third terminal 23.

The reverse current relay 90 has its first terminal 96a connected with the battery, the second terminal 91a connected with the generator and a third terminal III connected with the second terminal 22 of the voltage regulator. A series circuit is provided between the first and second terminals of the reverse current relay, this circuit includes a pair of normally open contacts I I4 and H5 and a series magnet coil I9, the contact II5 being permanently connected with the first terminal 98a and the other contact I I4 is connected through the magnet coil I I9 to the terminal 91a. Another circuit is connected with the second terminal 91a, said circuit including parallel circuits, one of which includes a shunt magnet coil III of the relay and rounded on the frame of the relay 90, and the other circuit is connected with the third terminal III of the relay.

The metal base 220 upon which the regulators and relay is mounted provides the ground connection with the battery, this base is engaged by the metal frame of the relay. The base supports a plurality of sockets for receiving the three terminals of the voltage regulator, the engagement of the sockets with the terminals of the regulator. The engagement of the terminal of the regulator with the sockets provides the detachable mounting for regulator upon the base. "The socket I23a receives the terminal 23 of the regulator, said socket being grounded to the base. The base provides a socket 2| Ia for the third terminal I II of the reverse current relay and an electrical connection 222 which is between the socket 2| Ia and the socket |22a for the second terminal 22 of the voltage regulator. The base provides a terminal 22|a for making connection with the field winding F of the generator and a connection 22I is located between the terminal 22 la and the socket |2|a for the first terminal 2| of the voltage regulator. The base also supports a resistance unit I34a grounded through the base. The resistance unit I34a is connected with the connection 22 I.

Fig. 14 shows another simplified diagram similar to Fig. 13 including a current regulator with a magnet coil 84 to be inserted in the battery charging circuit and has screw terminals 85 and 86 connected with the ends of the coil 84. A pair of regulating contacts 50a and 5|a are controlled by the coil 84. The contact 5Ia is connected with the terminal 8| and contact 50a with terminal 83. The base 220 is provided with sockets 85a and 88a respectively of the magnet coil 84 of the current regulator. A connection I85 connects the socket 850 with the terminal 91a of the reverse current relay and a connection I88 connects the socket 86a with the generator terminal IBfia on the base 220. The socket 86a receives a magnet coil terminal of the current regulator and sockets I2Ia and I83 respectively for receiving the current regulator contact terminals 8| and 83. A resistance unit I33 is connected at its ends to the sockets IBI and I83, the socket I8I being directly connected with the connection |3I to the generator field terminal on the base and the socket I83 being electrically connected with the socket I2I which receives the terminal 2| of the voltage regulator. The sockets I2I and I83 are interposed in the connections provided by the base between the socket I2I which receives the terminal of the voltage regulator and the resistance unit I34 of the voltage regulator and the generator field terminal I3Ia provided by the base.

While the embodiment of the present invention as herein disclosed, constitutes a preferred form, it is to be understood that other forms might be adopted, all coming within the scope of the claims which follow.

What is claimed is as follows:

1. An instrument assembly for use in a battery charging circuit including a generator and a storage battery comprising a voltage regulator, a cut-out relay and a base for supporting the regulator and relay and for making electrical connections therewith said base being one of a plurality of bases with which the voltage regulator and cutout relay may be used; said regulator having a pair of normally closed contacts for by-passing a generator field resistance, an armature for separating the contacts, an electromagnet for attracting the armature and having a main voltage responsive winding and a generator field current carrying winding, and having a circuit comprising a first plug and the field current winding and the contacts and a second plug, and having a circuit comprising the second plug and the voltage responsive winding and a third plug; said cutout relay having a pair of normally open contacts, an armature for closing them and an electro-magnet for attracting the armature having a current coil in series with the contacts, and having a generator voltage responsive coil, and having terminals for connecting the contacts and current coil into the battery charging circuit and having a plug connected in parallel with the voltage coil; said base carrying a terminal connected with the generator field, a resistance connected with the field terminal and with ground, and carrying first, second, third and fourth connector sockets for receiving, respectively, the first, second and third plugs of the voltage regulator, and the plug of the cut-out relay, and carrying means for connecting the first socket with the field terminal carried by'the base, means for connecting the second socket with ground, and means for connecting the third and fourth sockets.

2. The instrument assembly as defined {by claim 1 further characterized by the addition of a current regulator having normally closed contacts, an armature for separating them and an electromagnet for attracting the armature and having a current responsive winding, and having plugs connected, respectively, with the contacts and having terminals connected, respectively with the ends of the magnet winding; said base carrying the parts recited in claim 1 and the following in addition thereto: means for making connection with the current regulator magnet coil terminals and for connecting said coil into the battery charging circuit; a fifth socket and a sixth socket for receiving, respectively, the plugs of the current regulator, a second resistance connected between the fifth and sixth sockets, means for connecting the fifth socket directly with generator field terminal of the base, and a connector between the first and sixth sockets, the second resistance, the current regulator contacts and the fifth socket providing the means for connecting the first socket with the field terminal provided by the base.

3. A mounting support in combination with a plurality of electrical responsive devices for controlling a circuit from a generator to a battery comprising a support; a first group of conducting strips fixed to the support and having spaced yieldable sockets for receiving easily removable terminal plugs provided by the devices; a second group of conducting strips fixed to the support; interengaging means provided by at least one of the devices and the second group of conducting elements whereby said specified one device is normally prevented from removal from the support; and means for securing the specified one device in a fixed assembled relation; said devices when assembled in their respective positions being capable of controlling the electrical circuit from the generator to the battery.

WILLIAM J RADY. 

